Polymeric Membrane Sonication to Prevent Hollow Fiber Fouling
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Solution Overview
Problem
Existing methods for manufacturing polymeric membranes face challenges in independently controlling the incorporation of additives, leading to equipment buildup and inefficiencies in membrane formation, hollow fiber collapse, and increased downtime for cleaning.
Innovation Solution
Incorporating sonication at various stages of the membrane formation process, including the spinning block, precipitation bath, washing bath, and drying chamber, to enhance mixing, reduce additive accumulation, and prevent equipment fouling.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If additives are added to the spin mass to improve membrane properties, then desirable properties are achieved, but material buildup accumulates on spinning equipment
Solution Approach 1:
The patent extracts the harmful buildup from the spinning equipment by introducing a cleaning solution flow that removes accumulated material from the spinneret and spinning block surfaces, separating the membrane formation function from the contamination accumulation
Solution Approach 2:
The patent introduces a cleaning solution as an intermediary substance that mediates between the spin mass and the equipment surfaces, preventing direct adhesion of additives to the spinning block and enabling continuous operation
2Object-generated harmful factors
If cleaning is performed to remove buildup, then equipment fouling is reduced, but manufacturing operations must be shut down
Solution Approach 1:
The patent enables continuous cleaning action during membrane production by introducing a cleaning solution flow that operates simultaneously with the spin mass extrusion, eliminating shutdowns and maintaining continuous manufacturing
Solution Approach 2:
The patent applies preliminary cleaning action by introducing the cleaning solution flow at the point of buildup formation on the spinneret and spinning block, preventing accumulation before it becomes a problem rather than reacting to established fouling
3Object-generated harmful factors
If sonication is applied to reduce buildup, then equipment fouling is minimized, but process complexity increases
Solution Approach 1:
The patent applies ultrasonic vibration to the cleaning solution flow or spinning block surface to enhance the removal of additive buildup through cavitation and mechanical disruption, reducing fouling through physical vibration rather than chemical means
Solution Approach 2:
The patent replaces complex mechanical cleaning systems with ultrasonic vibration, substituting a simpler acoustic field application for what would otherwise require complex mechanical scraping or flushing mechanisms
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Sonication improves membrane formation by reducing equipment buildup, minimizing downtime, and enhancing the properties of polymeric membranes, such as hollow fiber membranes, used in dialysis and liquid filtration.
Implementation Method 1
The present invention involves the use of sonication during membrane manufacturing as a way to enhance the properties of the membrane as it forms
Implementation Method 2
A portion of this additive can result in material build up or accumulation on one or more pieces or portions of the equipment used in methods to form the polymer membrane
Implementation Method 3
Non-solvent induced phase separation (NIPS) is a method used to make porous membranes. During the phase separation process, spin mass (or spin dope) is exposed to a non-solvent (precipitation fluid) that causes the dissolved polymer to demix and precipitate out to form a membrane
Data Source
AI summary
The present invention relates to a method to make polymeric membranes that are preferably useful in dialysis, wherein the method conducts at least one membrane-forming step and/or post-forming processing step with the use of sonication. Polymeric membrane, such as polymeric hollow fiber membrane, having improved one or properties are further described.